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VDA

FMEA

Process:
Product:
Core team:
Operation / Part:
Function / Characteristic:
Failure Effect

Failure Mode

Page 1

Failure Cause

VDA

Factors 1 to 5
1, 2, 3, 4, 5, 6, 8, 9, 10, 12, 15,16, 18, 20, 24, 25, 27, 30, 32, 35, 36, 40, 45, 48, 50, 60, 64, 75, 80, 100, 125

Factors 1 to 10

1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 16, 18, 20, 21, 24, 25, 27, 28, 30, 32, 35, 36, 40, 42, 45, 48, 49, 50, 54

Page 2

VDA

Page 3

VDA

Page 4

VDA

Page 5

VDA

FMEA

Page:

Responsibility:

Number:

Prepared by:

Created:

Key Date:

Modified:

Preventive

Detection

Page 6

RPN Responsible / deadline

VDA

32, 35, 36, 40, 45, 48, 50, 60, 64, 75, 80, 100, 125

25, 27, 28, 30, 32, 35, 36, 40, 42, 45, 48, 49, 50, 54, 56, 60, 63, 64, 70, 72, 75, 80, 81, 84, 90, 96, 98, 100, 105, 108, 112, 120,

Page 7

VDA

Page 8

VDA

Page 9

VDA

Page 10

VDA

Page 11

VDA

84, 90, 96, 98, 100, 105, 108, 112, 120, 125, 126, 128, 135, 140, 144, 147, 150, 160, 162, 168, 175, 180, 189, 192, 196, 200, 2

Page 12

VDA

Page 13

VDA

Page 14

VDA

Page 15

VDA

Page 16

VDA

1
1
2
3
4
5
1

2
4
8
12
16
20
2

3
9
18
27
36
45
3

4
16
32
48
64
80
4

5
25
50
75
100
125
5

2
2

3
6

4
12

5
20

1
5

2
3

4
6

12
18

24
36

40
60

10
15

4
5

8
10
1

24
30
2

48
60
3

80
100
4

20
25
5

1
2
3
4
5

0, 162, 168, 175, 180, 189, 192, 196, 200, 210, 216, 224, 225, 240, 243, 245, 250, 252, 256, 270, 280, 288, 294, 300, 315, 320,
1
2
3
4
5

3
3
6
9
12
15
1

4
8
16
24
32
40
2

5
15
30
45
60
75
3

1
4
8
12
16
20
4

2
10
20
30
40
50
5

1
2
3
4
5

4
4
8
12
16
20
1

5
10
20
30
40
50
2

1
3
6
9
12
15
3

2
8
16
24
32
40
4

3
15
30
45
60
75
5

1
2
3
4
5

5
5
10
15
20
25
1

1
2
4
6
8
10
2

2
6
12
18
24
30
3

3
12
24
36
48
60
4

4
20
40
60
80
100
5

Page 17

VDA

1
2
3
4
5
6
7
8
9
10

1
1
2
3
4
5
6
7
8
9
10
1

2
4
8
12
16
20
24
28
32
36
40
2

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

1
2
3
4
5
6
7
8
9
10

2
2
4
6
8
10
12
14
16
18
20
1

3
6
12
18
24
30
36
42
48
54
60
2

4
12
24
36
48
60
72
84
96
108
120
3

5
20
40
60
80
100
120
140
160
180
200
4

6
30
60
90
120
150
180
210
240
270
300
5

1
2
3
4
5
6
7
8
9
10

3
3
6
9
12
15
18
21
24
27
30
1

4
8
16
24
32
40
48
56
64
72
80
2

5
15
30
45
60
75
90
105
120
135
150
3

6
24
48
72
96
120
144
168
192
216
240
4

7
35
70
105
140
175
210
245
280
315
350
5

1
2
3
4
5
6
7
8
9
10

4
4
8
12
16
20
24
28
32
36
40
1

5
10
20
30
40
50
60
70
80
90
100
2

6
18
36
54
72
90
108
126
144
162
180
3

7
28
56
84
112
140
168
196
224
252
280
4

8
40
80
120
160
200
240
280
320
360
400
5

5
5

6
12

7
21

8
32

9
45

Page 18

VDA
2
3
4
5
6
7
8
9
10

10
15
20
25
30
35
40
45
50
1

24
36
48
60
72
84
96
108
120
2

42
63
84
105
126
147
168
189
210
3

64
96
128
160
192
224
256
288
320
4

90
135
180
225
270
315
360
405
450
5

1
2
3
4
5
6
7
8
9
10

6
6
12
18
24
30
36
42
48
54
60
1

7
14
28
42
56
70
84
98
112
126
140
2

8
24
48
72
96
120
144
168
192
216
240
3

9
36
72
108
144
180
216
252
288
324
360
4

10
50
100
150
200
250
300
350
400
450
500
5

1
2
3
4
5
6
7
8
9
10

7
7
14
21
28
35
42
49
56
63
70
1

8
16
32
48
64
80
96
112
128
144
160
2

9
27
54
81
108
135
162
189
216
243
270
3

10
40
80
120
160
200
240
280
320
360
400
4

1
5
10
15
20
25
30
35
40
45
50
5

1
2
3
4
5
6
7
8
9
10

8
8
16
24
32
40
48
56
64
72
80
1

9
18
36
54
72
90
108
126
144
162
180
2

10
30
60
90
120
150
180
210
240
270
300
3

1
4
8
12
16
20
24
28
32
36
40
4

2
10
20
30
40
50
60
70
80
90
100
5

9
9
18
27
36

10
20
40
60
80

1
3
6
9
12

2
8
16
24
32

3
15
30
45
60

1
2
3
4

Page 19

VDA
5
6
7
8
9
10

1
2
3
4
5
6
7
8
9
10

45
54
63
72
81
90
1

100
120
140
160
180
200
2

15
18
21
24
27
30
3

40
48
56
64
72
80
4

75
90
105
120
135
150
5

10
10
20
30
40
50
60
70
80
90
100
1

1
2
4
6
8
10
12
14
16
18
20
2

2
6
12
18
24
30
36
42
48
54
60
3

3
12
24
36
48
60
72
84
96
108
120
4

4
20
40
60
80
100
120
140
160
180
200
5

Page 20

VDA

Page 21

VDA

1
1
2
3
4
5
1

2
4
8
12
16
20
2

3
9
18
27
36
45
3

4
16
32
48
64
80
4

5
25
50
75
100
125
5

2
2

3
6

4
12

5
20

1
5

3
4

4
6

12
18

24
36

40
60

10
15

5
1

8
10
1

24
30
2

48
60
3

80
100
4

20
25
5

1
2
3
4
5

252, 256, 270, 280, 288, 294, 300, 315, 320, 324, 336, 343, 350, 360, 378, 384, 392, 400, 405, 420, 432, 441, 448, 450, 480, 48
3
4
5
1
2

3
3
6
9
12
15
1

4
8
16
24
32
40
2

5
15
30
45
60
75
3

1
4
8
12
16
20
4

2
10
20
30
40
50
5

4
5
1
2
3

4
4
8
12
16
20
1

5
10
20
30
40
50
2

1
3
6
9
12
15
3

2
8
16
24
32
40
4

3
15
30
45
60
75
5

5
1
2
3
4

5
5
10
15
20
25
1

1
2
4
6
8
10
2

2
6
12
18
24
30
3

3
12
24
36
48
60
4

4
20
40
60
80
100
5

Page 22

VDA
6
36
72
108
144
180
216
252
288
324
360
6

7
49
98
147
196
245
294
343
392
441
490
7

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

10
100
200
300
400
500
600
700
800
900
1000
10

1
2
3
4
5
6
7
8
9
10

1
1
2
3
4
5
6
7
8
9
10
1

7
42
84
126
168
210
252
294
336
378
420
6

8
56
112
168
224
280
336
392
448
504
560
7

9
72
144
216
288
360
432
504
576
648
720
8

10
90
180
270
360
450
540
630
720
810
900
9

1
10
20
30
40
50
60
70
80
90
100
10

2
3
4
5
6
7
8
9
10
1

2
2
4
6
8
10
12
14
16
18
20
1

8
48
96
144
192
240
288
336
384
432
480
6

9
63
126
189
252
315
378
441
504
567
630
7

10
80
160
240
320
400
480
560
640
720
800
8

1
9
18
27
36
45
54
63
72
81
90
9

2
20
40
60
80
100
120
140
160
180
200
10

3
4
5
6
7
8
9
10
1
2

3
3
6
9
12
15
18
21
24
27
30
1

9
54
108
162
216
270
324
378
432
486
540
6

10
70
140
210
280
350
420
490
560
630
700
7

1
8
16
24
32
40
48
56
64
72
80
8

2
18
36
54
72
90
108
126
144
162
180
9

3
30
60
90
120
150
180
210
240
270
300
10

4
5
6
7
8
9
10
1
2
3

4
4
8
12
16
20
24
28
32
36
40
1

10
60

1
7

2
16

3
27

4
40

Page 23

5
5

VDA
120
180
240
300
360
420
480
540
600
6

14
21
28
35
42
49
56
63
70
7

32
48
64
80
96
112
128
144
160
8

54
81
108
135
162
189
216
243
270
9

80
120
160
200
240
280
320
360
400
10

1
6
12
18
24
30
36
42
48
54
60
6

2
14
28
42
56
70
84
98
112
126
140
7

3
24
48
72
96
120
144
168
192
216
240
8

4
36
72
108
144
180
216
252
288
324
360
9

5
50
100
150
200
250
300
350
400
450
500
10

6
7
8
9
10
1
2
3
4
5

6
6
12
18
24
30
36
42
48
54
60
1

2
12
24
36
48
60
72
84
96
108
120
6

3
21
42
63
84
105
126
147
168
189
210
7

4
32
64
96
128
160
192
224
256
288
320
8

5
45
90
135
180
225
270
315
360
405
450
9

6
60
120
180
240
300
360
420
480
540
600
10

7
8
9
10
1
2
3
4
5
6

7
7
14
21
28
35
42
49
56
63
70
1

3
18
36
54
72
90
108
126
144
162
180
6

4
28
56
84
112
140
168
196
224
252
280
7

5
40
80
120
160
200
240
280
320
360
400
8

6
54
108
162
216
270
324
378
432
486
540
9

7
70
140
210
280
350
420
490
560
630
700
10

8
9
10
1
2
3
4
5
6
7

8
8
16
24
32
40
48
56
64
72
80
1

4
24
48
72
96

5
35
70
105
140

6
48
96
144
192

7
63
126
189
252

8
80
160
240
320

Page 24

6
7
8
9
10
1
2
3
4

9
10
1
2

10
15
20
25
30
35
40
45
50
1

9
9
18
27
36

VDA
120
144
168
192
216
240
6

175
210
245
280
315
350
7

240
288
336
384
432
480
8

315
378
441
504
567
630
9

400
480
560
640
720
800
10

5
30
60
90
120
150
180
210
240
270
300
6

6
42
84
126
168
210
252
294
336
378
420
7

7
56
112
168
224
280
336
392
448
504
560
8

8
72
144
216
288
360
432
504
576
648
720
9

9
90
180
270
360
450
540
630
720
810
900
10

Page 25

3
4
5
6
7
8

10
1
2
3
4
5
6
7
8
9

45
54
63
72
81
90
1
10
10
20
30
40
50
60
70
80
90
100
1

VDA

Page 26

VDA

1
1
2
3
4
5
1

2
4
8
12
16
20
2

3
9
18
27
36
45
3

4
16
32
48
64
80
4

5
25
50
75
100
125
5

2
4

3
9

4
16

5
25

1
1

3
4

8
12

18
27

32
48

50
75

2
3

5
1

16
20
2

36
45
3

64
80
4

100
125
5

4
5
1

1
2
3
4
5

2, 400, 405, 420, 432, 441, 448, 450, 480, 486, 490, 500, 504, 512, 540, 560, 567, 576, 600, 630, 640, 648, 700, 720, 729, 800,
3
4
5
1
2

3
9
18
27
36
45
3

4
16
32
48
64
80
4

5
25
50
75
100
125
5

1
1
2
3
4
5
1

2
4
8
12
16
20
2

4
5
1
2
3

4
16
32
48
64
80
4

5
25
50
75
100
125
5

1
1
2
3
4
5
1

2
4
8
12
16
20
2

3
9
18
27
36
45
3

5
1
2
3
4

5
25
50
75
100
125
5

1
1
2
3
4
5
1

2
4
8
12
16
20
2

3
9
18
27
36
45
3

4
16
32
48
64
80
4

Page 27

VDA
2
4
8
12
16
20
24
28
32
36
40
2

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

6
36
72
108
144
180
216
252
288
324
360
6

7
49
98
147
196
245
294
343
392
441
490
7

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

3
6
12
18
24
30
36
42
48
54
60
2

4
12
24
36
48
60
72
84
96
108
120
3

5
20
40
60
80
100
120
140
160
180
200
4

6
30
60
90
120
150
180
210
240
270
300
5

7
42
84
126
168
210
252
294
336
378
420
6

8
56
112
168
224
280
336
392
448
504
560
7

9
72
144
216
288
360
432
504
576
648
720
8

10
90
180
270
360
450
540
630
720
810
900
9

4
8
16
24
32
40
48
56
64
72
80
2

5
15
30
45
60
75
90
105
120
135
150
3

6
24
48
72
96
120
144
168
192
216
240
4

7
35
70
105
140
175
210
245
280
315
350
5

8
48
96
144
192
240
288
336
384
432
480
6

9
63
126
189
252
315
378
441
504
567
630
7

10
80
160
240
320
400
480
560
640
720
800
8

1
9
18
27
36
45
54
63
72
81
90
9

5
10
20
30
40
50
60
70
80
90
100
2

6
18
36
54
72
90
108
126
144
162
180
3

7
28
56
84
112
140
168
196
224
252
280
4

8
40
80
120
160
200
240
280
320
360
400
5

9
54
108
162
216
270
324
378
432
486
540
6

10
70
140
210
280
350
420
490
560
630
700
7

1
8
16
24
32
40
48
56
64
72
80
8

2
18
36
54
72
90
108
126
144
162
180
9

6
12

7
21

8
32

9
45

10
60

1
7

2
16

3
27

Page 28

VDA
24
36
48
60
72
84
96
108
120
2

42
63
84
105
126
147
168
189
210
3

64
96
128
160
192
224
256
288
320
4

90
135
180
225
270
315
360
405
450
5

120
180
240
300
360
420
480
540
600
6

14
21
28
35
42
49
56
63
70
7

32
48
64
80
96
112
128
144
160
8

54
81
108
135
162
189
216
243
270
9

7
14
28
42
56
70
84
98
112
126
140
2

8
24
48
72
96
120
144
168
192
216
240
3

9
36
72
108
144
180
216
252
288
324
360
4

10
50
100
150
200
250
300
350
400
450
500
5

1
6
12
18
24
30
36
42
48
54
60
6

2
14
28
42
56
70
84
98
112
126
140
7

3
24
48
72
96
120
144
168
192
216
240
8

4
36
72
108
144
180
216
252
288
324
360
9

8
16
32
48
64
80
96
112
128
144
160
2

9
27
54
81
108
135
162
189
216
243
270
3

10
40
80
120
160
200
240
280
320
360
400
4

1
5
10
15
20
25
30
35
40
45
50
5

2
12
24
36
48
60
72
84
96
108
120
6

3
21
42
63
84
105
126
147
168
189
210
7

4
32
64
96
128
160
192
224
256
288
320
8

5
45
90
135
180
225
270
315
360
405
450
9

9
18
36
54
72
90
108
126
144
162
180
2

10
30
60
90
120
150
180
210
240
270
300
3

1
4
8
12
16
20
24
28
32
36
40
4

2
10
20
30
40
50
60
70
80
90
100
5

3
18
36
54
72
90
108
126
144
162
180
6

4
28
56
84
112
140
168
196
224
252
280
7

5
40
80
120
160
200
240
280
320
360
400
8

6
54
108
162
216
270
324
378
432
486
540
9

10
20
40
60
80

1
3
6
9
12

2
8
16
24
32

3
15
30
45
60

4
24
48
72
96

5
35
70
105
140

6
48
96
144
192

7
63
126
189
252

Page 29

VDA
100
120
140
160
180
200
2

15
18
21
24
27
30
3

40
48
56
64
72
80
4

75
90
105
120
135
150
5

120
144
168
192
216
240
6

175
210
245
280
315
350
7

240
288
336
384
432
480
8

315
378
441
504
567
630
9

1
2
4
6
8
10
12
14
16
18
20
2

2
6
12
18
24
30
36
42
48
54
60
3

3
12
24
36
48
60
72
84
96
108
120
4

4
20
40
60
80
100
120
140
160
180
200
5

5
30
60
90
120
150
180
210
240
270
300
6

6
42
84
126
168
210
252
294
336
378
420
7

7
56
112
168
224
280
336
392
448
504
560
8

8
72
144
216
288
360
432
504
576
648
720
9

Page 30

VDA

Page 31

VDA

576, 600, 630, 640, 648, 700, 720, 729, 800, 810, 900, 1000

Page 32

VDA
10
100
200
300
400
500
600
700
800
900
1000
10

1
2
3
4
5
6
7
8
9
10

1
1
2
3
4
5
6
7
8
9
10
1

2
4
8
12
16
20
24
28
32
36
40
2

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

1
10
20
30
40
50
60
70
80
90
100
10

2
3
4
5
6
7
8
9
10
1

2
4
8
12
16
20
24
28
32
36
40
2

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

6
36
72
108
144
180
216
252
288
324
360
6

2
20
40
60
80
100
120
140
160
180
200
10

3
4
5
6
7
8
9
10
1
2

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

6
36
72
108
144
180
216
252
288
324
360
6

7
49
98
147
196
245
294
343
392
441
490
7

3
30
60
90
120
150
180
210
240
270
300
10

4
5
6
7
8
9
10
1
2
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

6
36
72
108
144
180
216
252
288
324
360
6

7
49
98
147
196
245
294
343
392
441
490
7

8
64
128
192
256
320
384
448
512
576
640
8

5
25

6
36

7
49

8
64

9
81

4
40

Page 33

VDA
80
120
160
200
240
280
320
360
400
10

6
7
8
9
10
1
2
3
4

50
75
100
125
150
175
200
225
250
5

72
108
144
180
216
252
288
324
360
6

98
147
196
245
294
343
392
441
490
7

128
192
256
320
384
448
512
576
640
8

162
243
324
405
486
567
648
729
810
9

5
50
100
150
200
250
300
350
400
450
500
10

6
7
8
9
10
1
2
3
4
5

6
36
72
108
144
180
216
252
288
324
360
6

7
49
98
147
196
245
294
343
392
441
490
7

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

10
100
200
300
400
500
600
700
800
900
1000
10

6
60
120
180
240
300
360
420
480
540
600
10

7
8
9
10
1
2
3
4
5
6

7
49
98
147
196
245
294
343
392
441
490
7

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

10
100
200
300
400
500
600
700
800
900
1000
10

1
1
2
3
4
5
6
7
8
9
10
1

7
70
140
210
280
350
420
490
560
630
700
10

8
9
10
1
2
3
4
5
6
7

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

10
100
200
300
400
500
600
700
800
900
1000
10

1
1
2
3
4
5
6
7
8
9
10
1

2
4
8
12
16
20
24
28
32
36
40
2

9
81
162
243
324

10
100
200
300
400

1
1
2
3
4

2
4
8
12
16

3
9
18
27
36

8
80
160
240
320

9
10
1
2

Page 34

VDA
400
480
560
640
720
800
10
9
90
180
270
360
450
540
630
720
810
900
10

3
4
5
6
7
8

10
1
2
3
4
5
6
7
8
9

405
486
567
648
729
810
9

500
600
700
800
900
1000
10

5
6
7
8
9
10
1

20
24
28
32
36
40
2

45
54
63
72
81
90
3

10
100
200
300
400
500
600
700
800
900
1000
10

1
1
2
3
4
5
6
7
8
9
10
1

2
4
8
12
16
20
24
28
32
36
40
2

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

Page 35

VDA

Page 36

VDA

Page 37

VDA
6
36
72
108
144
180
216
252
288
324
360
6

7
49
98
147
196
245
294
343
392
441
490
7

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

10
100
200
300
400
500
600
700
800
900
1000
10

7
49
98
147
196
245
294
343
392
441
490
7

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

10
100
200
300
400
500
600
700
800
900
1000
10

1
1
2
3
4
5
6
7
8
9
10
1

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

10
100
200
300
400
500
600
700
800
900
1000
10

1
1
2
3
4
5
6
7
8
9
10
1

2
4
8
12
16
20
24
28
32
36
40
2

9
81
162
243
324
405
486
567
648
729
810
9

10
100
200
300
400
500
600
700
800
900
1000
10

1
1
2
3
4
5
6
7
8
9
10
1

2
4
8
12
16
20
24
28
32
36
40
2

3
9
18
27
36
45
54
63
72
81
90
3

10
100

1
1

2
4

3
9

4
16

Page 38

VDA
200
300
400
500
600
700
800
900
1000
10

2
3
4
5
6
7
8
9
10
1

8
12
16
20
24
28
32
36
40
2

18
27
36
45
54
63
72
81
90
3

32
48
64
80
96
112
128
144
160
4

1
1
2
3
4
5
6
7
8
9
10
1

2
4
8
12
16
20
24
28
32
36
40
2

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

2
4
8
12
16
20
24
28
32
36
40
2

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

6
36
72
108
144
180
216
252
288
324
360
6

3
9
18
27
36
45
54
63
72
81
90
3

4
16
32
48
64
80
96
112
128
144
160
4

5
25
50
75
100
125
150
175
200
225
250
5

6
36
72
108
144
180
216
252
288
324
360
6

7
49
98
147
196
245
294
343
392
441
490
7

4
16
32
48
64

5
25
50
75
100

6
36
72
108
144

7
49
98
147
196

8
64
128
192
256

Page 39

VDA
80
96
112
128
144
160
4

125
150
175
200
225
250
5

180
216
252
288
324
360
6

245
294
343
392
441
490
7

320
384
448
512
576
640
8

5
25
50
75
100
125
150
175
200
225
250
5

6
36
72
108
144
180
216
252
288
324
360
6

7
49
98
147
196
245
294
343
392
441
490
7

8
64
128
192
256
320
384
448
512
576
640
8

9
81
162
243
324
405
486
567
648
729
810
9

Page 40

Ratings description
SYSTEM

significance

detection

occurrence

1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10

not perceptible
small
small
medium
medium
medium
significant
significant
very significant
very significant
very probable
probable
medium
medium
medium
small
small
small
very small
improbable
improbable
very small
very small
small
small
small
medium
medium
high
high

1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7

None
Very Minor
Minor
Very Low
Low
Moderate
High
Very High
Hazardous-with warning
Hazardous-without warning
Almost Certain
Very High
High
Moderately High
Moderate
Low
Very Low

DESIGN / MACHINE

significance

detection

Page 41

detection

Ratings description

occurrence

8
9
10
1
2
3
4
5
6
7
8
9
10

Remote
Very Remote
Absolute Uncertainty
Remote
Low
Low
Moderate
Moderate
Moderate
High
High
Very High
Very High

1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10

None
Very Minor
Minor
Very Low
Low
Moderate
High
Very High
Hazardous-with warning
Hazardous-without warning
Almost Certain
Very High
High
Moderately High
Moderate
Low
Very Low
Remote
Very Remote
Almost impossible
Remote
Very Low
Low
Moderate
Moderate
Moderate
High
High
Very High
Very High

PROCESS

significance

detection

occurrence

Page 42

Ratings description

Page 43

Ratings description

SYSTEM
not perceptible It is improbable that this failure will result in a perceptible change in the performance of the system. Th
small This failure is not significant. The customer will not be inconvenienced by a the malfunction of the system.
small This failure is not significant. The customer will not be inconvenienced by a the malfunction of the system.
medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunctio
medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunctio
medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunctio
significant Significant failure that causes a total malfunction of the system. The customer will not be able to use the sys
significant Significant failure that causes a total malfunction of the system. The customer will not be able to use the sys
very significant Significant failure that causes total inoperabilty of the system and possible malfunction of the safety me
very significant Significant failure that causes total inoperabilty of the system and possible malfunction of the safety me
very probable It is improbable that the failure will not be recognized during testing. Chance of discovery >= 99.99%
probable It is improbable that the failure will not be recognized during testing. Chance of discovery >= 99.7%
medium Chance of discovery >= 99.7%.
medium Chance of discovery >= 99.7%.
medium Chance of discovery >= 99.7%.
small Chance of discovery >= 98%.
small Chance of discovery >= 98%.
small Chance of discovery >= 98%.
very small Chance of discovery >= 90%
improbable Chance of discovery < 90%
improbable It is improbable for this failure to occur. Chance of failure <= 1/100000
very small This design is only slightly different from earlier proven designs. Chance of failure <= 1/20000
very small This design is only slightly different from earlier proven designs. Chance of failure <= 1/10000
small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <
small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <
small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <
medium This design is only slightly different from earlier proven designs which caused problems. Chance of failure <=
medium This design is only slightly different from earlier proven designs which caused problems. Chance of failure <=
high This design is almost certain to cause problems. Chance of failure <= 1/10
high This design is almost certain to cause problems. Chance of failure <= 1/2
DESIGN / MACHINE
No Effect
Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by discriminating customer.
Minor Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by average customer.
Very Low Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by most customers.
Low Vehicle/item operable, but Comfort/Convenience item(s) operable at reduced level of performance. Customer exp
Moderate Vehicle/item operable, but Comfort/Convenience item(s) inoperable. Customer experiences discomfort.
High Vehicle/item operable, but at reduced level of performance. Customer dissatisfied.
Very High Vehicle/item inoperable, with loss of primary function.
Hazardous-with warning Very high severity ranking when a potential failure mode affects safe vehicle operation and/or
Hazardous-without warning Very high severity ranking when a potential failure mode affects safe vehicle operation and
Almost Certain Design Control will almost certainly detect a potential cause/mechanism and subsequent failure mode.
Very High Very high chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
High High chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Moderately High Moderately high chance the Design Control will detect a potential cause/mechanism and subsequent f
Moderate Moderate chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Low Low chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Very Low Very low chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.

Page 44

Ratings description

Remote Remote chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Very Remote Very remote chance the Design Control will detect a potential cause/mechanism and subsequent failure m
Absolute Uncertainty Design Control will not and/or can not detect a potential cause/mechanism and subsequent failure
Remote Failure is unlikely Possible Failure Rate <=1 in 1,500,000
Low Relatively few failures Possible Failure Rate 1 in 150,000
Low Relatively few failures Possible Failure Rate 1 in 15,000
Moderate Occasional failures Possible Failure Rate 1 in 2,000
Moderate Occasional failures Possible Failure Rate 1 in 400
Moderate Occasional failures Possible Failure Rate 1 in 80
High Repeated failures Possible Failure Rate 1 in 20
High Repeated failures Possible Failure Rate 1 in 8
Very High Failure is almost inevitable Possible Failure Rate 1 in 3
Very High Failure is almost inevitable Possible Failure Rate >=1 in 2
PROCESS
None No Effect.
Very Minor Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-li
Minor Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line bu
Very Low Minor disruption to production line. The product may have to be sorted and a portion (less than 100%) rework
Low Minor disruption to production line. 100% of product may have to be reworked. Fit & Finish/Squeak & Rattle item d
Moderate Minor disruption to production line. A portion (less than 100%) of the product may have to be scrapped (no so
High Minor disruption to production line. Product may have to be sorted and a portion (less than 100%) scrapped. Veh
Very High Major disruption to production line. 100% of product may have to be scrapped. Vehicle/item inoperable, loss
Hazardous-with warning May endanger machine of assembly operator. Very high severity ranking when a potential failu
Hazardous-without warning May endanger machine of assembly operator. Very high severity ranking when a potential f
Almost Certain
Design control(s) almost certain to detect the failure mode. Reliable detection controls are known w
Very High Very high likelihood current control(s) will detect failure mode.
High High likelihood current control(s) will detect failure mode.
Moderately High Moderately high likelihood current control(s) will detect failure mode.
Moderate Moderate likelihood current control(s) will detect failure mode.
Low Low likelihood current control(s) will detect failure mode.
Very Low Very low likelihood current control(s) will detect failure mode.
Remote Remote likelihood current control(s) will detect failure mode.
Very Remote Very remote likelihood current control(s) will detect failure mode.
Almost impossible No known control(s) available to detect failure mode.
Remote
Failure is unlikely. No failures ever associated with almost identical processes.
Possible Failure Rat
Very Low Only isolated failures associated with almost identical processes. Possible Failure Rate 1 in 150,000 Cpk >=
Low Isolated failures associated with similar processes. Possible Failure Rate 1 in 15,000 Cpk >= 1.33
Moderate Generally associated with processes similar to previous processes which have experienced occasional failur
Moderate Generally associated with processes similar to previous processes which have experienced occasional failur
Moderate Generally associated with processes similar to previous processes which have experienced occasional failur
High Generally associated with processes similar to previous processes that have often failed. Possible Failure Rate 1
High Generally associated with processes similar to previous processes that have often failed. Possible Failure Rate 1
Very High Failure is almost inevitable. Possible Failure Rate 1 in 3 Cpk >= 0.33
Very High Failure is almost inevitable. Possible Failure Rate >= 1 in 2 Cpk < 0.33

Alta (1 de 20
Alta (1 de 8)

Page 45

Ratings description

Muy alta (1 d

Page 46

Ratings description

e performance of the system. The customer is not likely to notice this failure.
malfunction of the system.
malfunction of the system.
e or she will notice the malfunctioning of the system.
e or she will notice the malfunctioning of the system.
e or she will notice the malfunctioning of the system.
mer will not be able to use the system. Safety mechanisms of the system are not impaired.
mer will not be able to use the system. Safety mechanisms of the system are not impaired.
sible malfunction of the safety mechanisms.
sible malfunction of the safety mechanisms.
hance of discovery >= 99.99%
e of discovery >= 99.7%

of failure <= 1/20000


of failure <= 1/10000
some cases. Chance of failure <= 1/2000
some cases. Chance of failure <= 1/1000
some cases. Chance of failure <= 1/200
ed problems. Chance of failure <= 1/100
ed problems. Chance of failure <= 1/20

el of performance. Customer experiences some dissatisfaction.


mer experiences discomfort.

cts safe vehicle operation and/or involves noncompliance with government regulation with warning.
affects safe vehicle operation and/or involves noncompliance with government regulation without warning.
m and subsequent failure mode.
m and subsequent failure mode.
bsequent failure mode.
use/mechanism and subsequent failure mode.
m and subsequent failure mode.
sequent failure mode.
m and subsequent failure mode.

Page 47

Ratings description

and subsequent failure mode.


chanism and subsequent failure mode.
mechanism and subsequent failure mode; or there is no Design Control.

Notes_Spanish
ay have to be reworked on-line but out-of-station. Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by average customers.
Ninguno Sin efecto
Muy menor Puede estropear levemente la linea de produccin
Menor Puede estropear levemente la linea de produccin
Muy bajo Puede estropear levemente la linea de produccin
Bajo Puede estropear levemente la linea de produccin
Moderado Puede estropear levemente la linea de produccin
Alto Puede estropear levemente la linea de produccin
Muy alto Puede estropear la linea de produccin
Aleatoriamente con aviso Puede daar la mquina o la operacin de ensamblaje
Aleatoriamente sin aviso Puede daar la mquina o la operacin de ensamblaje

Casi siempre Los controles actuales detectarn el fallo casi siempre


Muy Alta Muy normalmente los controles actuales detectarn el fallo
Alta Normalmente los controles actuales detectarn el fallo
Moderada alta Los controles actuales detectarn el fallo muy a menudo
Moderada Los controles actuales detectarn el fallo a menudo
Baja Difilcilmente los controles actuales detectarn el fallo
Muy baja Muy dificilmente los controles actuales detectarn el fallo
Remota Remotamente los controles detectarn el fallo
Muy remota Muy remotamente los controles actuales detectarn el fallo
Casi imposible No se conocen controles para detectar el fallo
Remota (1 en 1,500,000) El fallo es casi imposible Cpk>=1.67
Muy baja (1 en 150,000) Asociados a idticos procesos Cpk=1.5
Baja (1 en 15,000) Asociados a procesos similares Cpk>=1.33
Moderada (1 en 2000) Asociados a procesos anteriores en baja proporcin Cpk>=1.17
Moderada (1 en 400) Asociados a procesos anteriores en baja proporcin Cpk>=1.00
Moderada (1 en 80) Asociados a procesos anteriores en baja proporcin Cpk>=0.88
Alta (1 de 20) Asociados a procesos anteriores Cpk>=0.67
Alta (1 de 8) Asociados a procesos anteriores Cpk>=0.51

Page 48

Ratings description
Muy alta (1 de 3) El fallo es casi inevitable Cpk=0.33
Muy alta (>=1 de 2) El fallo es casi inevitable Cpk<0.33

Page 49

Ratings description

Page 50

Ratings description

t conform. Defect noticed by average customers.

Page 51

FMEA
Process

Type/Model/Fabrication/Load:
Item Code:
Beer making (based on Indian Pale Ale)
Revision State:

Responsible:

FMEA/Process Step:
Sterilisation

Item Code:

Responsible:

Revision State:

Company:

Company:

Effects
S
Failure Mode
Causes
Preventive Action
Process Element: OPERATION UNDER ANALYSIS - e.g. welding
Function: WHAT YOU INTEND TO ACHIEVE AT THIS STATION - e.g. weld as per drawing
Outcome of
the Failure
Mode e.g
Reduced
structural
Integrity

Failure Cause insufficient


acetylene gas

Failure Mode - Poor


Failure Cause - Wire
weld penetration
feed blocked

Fails crash
test

10

Outcome of
the Failure
Mode e.g
Reduced
structural
Integrity

Fails crash
test

10

Coded Welders
4
Way to prevent the
cause!
TPM

Failure Cause - No
gas shield

Failure Mode Excess weld


penetration

Failure Cause - Wire


feed too slow

Company welding
procedures]

Number: 1.1

Page:

Created: 13/03/2013

Created: 13/03/2013
Modified: 13/03/2013
Detection Action

RPN

80

r drawing
Gas checked
before shift
First off inspecion

R/D

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